Invensys has reviewed the issue described in this Product Alert Notice and determined that, if no action is taken to resolve the issues described in this notice, there is a potential risk of harm to people, property, and/or the environment. Third-party integrators and distributors of Triconex® systems need to notify their end-user customers of this issue. All end-users should immediately review and analyze the impact of this issue to their applications. If this issue is found to be applicable, remedial actions should be taken to ensure the continued safe operation of affected systems.

Subject: Possible Spurious Output Transitions on the Tricon 3625 24V Digital Output Modules

Affected Products

The following modules used in TriconTM system versions 10.2.0-10.2.5, 10.3.0-10.3.3, 10.4.0-10.4.3, and 10.5.0-10.5.2 are affected:

• Model 3625 24V Digital Output Module

• Model 3625A 24V Digital Output Module

• Model 3625N 24V Digital Output Module

Problem Description

When pOints 1, 2, 17, and 18 on an affected module are ALL commanded OFF, one or both of the following issues may occur:

1. In the presence of specific output voter faults, a point on an affected module may transition to the opposite of the commanded state for as long as 227 milliseconds.

This issue has not been reported in the field.

2. When a Tricon controller is operated with a hot-spare Model 3625/A/N module installed, multiple output points on the affected modules may simultaneously transition to the opposite of the commanded state. The duration of the output transitions can last as long as 227 milliseconds.

Affected modules with all points commanded OFF are immune to these transitions.

This issue has been reported in the field only on affected modules where a hot-spare module is also installed in the slot, AND pOints 1, 2, 17, and 18 are all commanded OFF.

Background

Investigation of the problem discovered an initialization error in the output register circuitry. The output register is periodically reset by the watchdog timeout diagnostic routine.

When an output register watchdog reset occurs, the register may not be immediately re-initialized to the correct commanded values. When a watchdog timeout diagnostic routine runs on a second channel before the first channel has completely recovered from its watchdog diagnostic routine, then spurious output transitions are possible.
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